Multicolor Fixture Finishes

ABSTRACT

A plumbing fixture having a multi-color appearance includes a first portion including a first finish having a first appearance and a second portion including a second portion having a second appearance that differs from the first appearance. The plumbing fixture further includes a transition region between the first portion and the second portion, wherein the appearance of the third region is graduated from the first appearance to the second appearance between a first end of the transition region adjacent the first portion and a second end of the transition region adjacent the second portion. The plumbing fixture has an ombré appearance as a result of the graduated transition between the first portion and the second portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/230,546, filed on Dec. 21, 2018, which claims the benefit of andpriority to U.S. Provisional Application No. 62/614,385, filed on Jan.6, 2018. The entire disclosures of U.S. patent application Ser. No.16/230,546 and U.S. Provisional Patent App. No. 62/614,385 are herebyincorporated by reference herein.

BACKGROUND

The present application relates to multi-colored finishes for fixtures,and fixtures having such finishes. More specifically, disclosed hereinare methods of applying such finishes to achieve a surface appearancethat transitions in color, shade, or lightness from one region toanother, typically in a graduated fashion.

SUMMARY

At least one embodiment relates to a method of applying a multi-colorfinish to a plumbing fixture that includes depositing a first coating onthe plumbing fixture; selectively applying a masking material in agraduated fashion over at least a portion of the first coating to definea gradient from a first portion of the plumbing fixture that issubstantially completely covered by the masking material to a secondportion of the plumbing fixture that has substantially no maskingmaterial; depositing a second coating over the masking material; andremoving the masking material from the plumbing fixture such that theplumbing fixture has a surface finish including a transition regionrepresenting a gradual transition between the first coating and thesecond coating.

In some exemplary embodiments, the transition region includes a firstpercentage of the first coating and a second percentage of the secondcoating.

In some exemplary embodiments, the first percentage is in a range ofabout 5% to about 95% with the remaining balance as the secondpercentage.

In some exemplary embodiments, the transition region includes aplurality of percentages of the first coating and a plurality ofpercentages of the second coating.

In some exemplary embodiments, the first coating defines a first finishhaving a first appearance and the second coating defines a second finishhaving a second appearance that is different from the first appearance.

In some exemplary embodiments, the first finish and the second finishare selected from at least one of polished chrome, brushed chrome,polished French gold, polished titanium, brushed titanium, polished rosegold, polished modern gold, polished tungsten, polished modern brass,satin titanium, polished satin chrome, satin bronze, polished brass,satin brass, oil-rubbed bronze, polished nickel, brushed nickel, ormatte black.

In some exemplary embodiments, the step of depositing the first coatingand the step of depositing the second coating are conducted using atleast one of physical vapor deposition (PVD), chemical vapor deposition(CVD), atomic layer deposition (ALD), electroplating, dip coating, orspray coating.

In some exemplary embodiments, the step of depositing the first coatingand the step of depositing the second coating are each conducted usingphysical vapor deposition (PVD), and wherein the PVD is conducted as theplumbing fixture is rotated on a turntable.

In some exemplary embodiments, the PVD is selected from at least one ofcathodic-arc evaporation, sputter deposition, or high-impulse powermagnetron sputtering (HIPIMS).

In some exemplary embodiments, the masking material includes at leastone of molybdenum disulfide, tungsten disulfide, boron nitride, orgraphite.

In some exemplary embodiments, after the step of masking, the maskingmaterial is cured at a temperature in a range of about 60° C. to about250° C. for a time in a range of about 15 minutes to about 120 minutes.

In some exemplary embodiments, the masking material is applied by atechnique selected from the group consisting of printing, powdercoating, painting, spraying, dipping, brushing, and dry-powder tumbling.

In some exemplary embodiments, the masking material is applied byspraying, and the spraying is conducted as the plumbing fixture isrotated on a turntable.

In some exemplary embodiments, the step of depositing the second coatingcomprises depositing the second coating on the first portion and thesecond portion.

In some exemplary embodiments, the step of removing the masking materialcomprises washing the plumbing fixture using at least one of awater-based wash, an acid wash, or an organic solvent-based wash.

Another exemplary embodiment relates to a multi-color plumbing fixtureincluding a surface finish. The surface finish includes a firstappearance, a second appearance, and a transition region. The firstappearance is on a first portion of the plumbing fixture. The secondappearance is on a second portion of the plumbing fixture, wherein thesecond appearance is different from the first appearance. The transitionregion is disposed between the first portion and the second portion,wherein the transition region represents a gradual transition betweenthe first appearance and the second appearance.

In some exemplary embodiments, the first appearance is defined by afirst coating, and wherein the second appearance is defined by a maskingmaterial.

In some exemplary embodiments, the first appearance is defined by afirst coating having a first finish, and wherein the second appearanceis defined by a second coating having a second finish that is differentfrom the first finish.

In some exemplary embodiments, the transition region includes a firstpercentage of the first coating and a second percentage of the secondcoating.

In some exemplary embodiments, the transition region includes aplurality of percentages of the first coating and a plurality ofpercentages of the second coating.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow diagram illustrating a method of applying a multi-colorfinish to a fixture according to an exemplary embodiment.

FIG. 2 illustrates a plumbing fixture including a masking material and afirst coating according to an exemplary embodiment.

FIG. 3 is illustrates a plumbing fixture including a masking materialand a first coating according to another exemplary embodiment.

FIG. 4 illustrates a faucet plumbing fixture having a final ombréappearance according to an exemplary embodiment.

FIG. 5 illustrates a process for masking a portion of a plumbingfixture, according to an exemplary embodiment.

FIG. 6 illustrates a mask-less configuration for depositing a coating ina vacuum chamber, according to another exemplary embodiment.

FIG. 7 illustrates a mask-less configuration for depositing a coating ina vacuum chamber, according to another exemplary embodiment.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented here. It will be readily understood that the aspects of thepresent disclosure, as generally described herein, and illustrated inthe figures, can be arranged, substituted, combined, and designed in awide variety of different configurations, all of which are explicitlycontemplated and made part of this disclosure.

As used in the present disclosure, the term “ombré” may be used todescribe a visual effect in which a color, shade, or lightness graduallytransitions from one region to another. For example, a color may begraduated from darker to lighter from one region to the next. The actualgraduation may be from a darker color to a lighter color, from one shadeto another, or to any combination of colors or shades. While ombréeffects have been used most frequently in the textile and hairindustries, they have not been adapted for use in connection withsurfaces having irregular patterns or shapes, and specifically forplumbing fixtures that require a resilient finish that is intended towithstand ordinary usage in such environments.

It would be advantageous to provide a novel method for applyingmulti-color finishes to fixtures, and to produce products employing suchfinishes to provide a unique and heretofore unused finish for suchproducts. These and other advantageous features will be apparent tothose reviewing the present disclosure.

The present disclosure provides for a method of forming a multicolorfinish to a fixture, and fixtures having such finish. Referring to theexemplary embodiment of FIG. 1, a first step 100 of the disclosedprocess includes providing a fixture, shown as a plumbing fixture 10, asa substrate upon which the multicolor finish will be applied. Theplumbing fixture is not meant to be limited and may be any householdplumbing fixture associated with delivering and draining water. Theplumbing fixture may be at least one of faucets for sinks, tubs,whirlpools, shower heads, spas, soap dispensers, and the like; faucethandles; faucet accessories such as fluid conduits (e.g., water piping,hoses, etc.); or water containers or vessels such as sinks, tubs,whirlpools, spas, etc. In another embodiment, the multicolor finish mayalso be applied to other fixtures, such as bathroom or kitchen fixturessuch as towel holders, lighting fixtures, or ventilation fixtures.Moreover, the surface finish may be applied to a surface of the fixturethat is made from at least one of a low-corrosive metal or metal alloys(e.g., tungsten, titanium, chrome, pewter, copper, bronze, brass,stainless steel, zinc alloys), ceramic (e.g., porcelain), glass,plastic, or combinations thereof.

A second step 200 of the process according to the embodiment of FIG. 1includes depositing a first coating 20 on the plumbing fixture 10 toobtain a first finish having a first appearance. In one embodiment, thestep of depositing the first coating includes depositing the firstcoating on the entire surface area of the plumbing fixture. In anotherembodiment, only a portion of the surface area of the fixture is coatedwith the first finish. The first finish may be at least one of apolished metal, brushed metal, gold-plated, oil-rubbed metal, satinmetals or combinations thereof. Non-limiting examples of the firstfinish include polished chrome, brushed chrome, polished French gold,polished titanium, brushed titanium, polished rose gold, polished moderngold, polished tungsten, polished modern brass, satin titanium, polishedsatin chrome, satin bronze, polished brass, satin brass, oil-rubbedbronze, polished nickel, brushed nickel, matte black, and the like.

The step of depositing the first coating may be conducted using at leastone of a vacuum deposition (physical vapor deposition, PVD; chemicalvapor deposition, CVD; atomic layer deposition, ALD), electroplating,dip coating, or spray coating process. In one embodiment, PVD is used asthe deposition technique for forming the first coating on the plumbingfixture.

PVD vacuum deposition processes are advantageous because they involve noaqueous component and are more environmentally friendly and economicalthan wet chemical processes. PVD coatings are typically harder and morecorrosion-resistant than coatings applied by electroplating. Most PVDcoatings have high temperature and good impact strength, excellentabrasion resistance, and are durable such that protective topcoats areoptional. PVD deposition processes include at least one of cathodic arcevaporation, electron beam (e-beam) PVD, evaporative deposition,pulsed-laser deposition, sputter deposition, ion plating, orpulsed-electron deposition. In typical PVD processes, a material isvaporized from a solid source and transported in a vacuum environment asa vapor to a substrate where it condenses, forming a coating. The vacuumenvironment is configured such that the mean free path for collisionbetween particles is on the order of the dimensions of the processingchamber or through a low-pressure environment of gas or plasma (ionizedgas).

In some embodiments, the PVD process of the first coating is a reactivedeposition process whereby the depositing species reacts with a gasspecies in the processing environment to form a compound prior todepositing (e.g., nitrogen reacting with depositing titanium to form acoating of TiN (having a gold appearance)). Decorative/wear PVD coatingsfor plumbing fixtures include TiN (having a gold appearance), ZrN(having a brass-like appearance), TiC (having a black appearance), TICN(having an “anthracite gray” appearance), ZrCN (having a nickel-likeappearance), ZrCrCN (having a brass-like appearance), and ZrCrN (havinga gold or rose-gold appearance). In one embodiment, a thickness of thefirst coating may vary in a range of about 100 nm to about 2000 nm. Insome embodiments, prior to PVD deposition, at least one thin seed orprimer layer may be deposited on the plumbing fixture to achieveenhanced bonding characteristics with the subsequently PVD coating. Forsurfaces that are non-planar, the plumbing fixture may be set on aturntable that manually or automatically rotates as the first coating isapplied.

In some embodiments, the vacuum deposition of the first coating isconducted using vacuum evaporation, whereby an evaporation materialsource is thermally vaporized from a container heated eitherelectrically or by an e-beam. The vaporization is conducted such thatthe trajectory of the vaporized material is line-of-sight. The vacuumenvironment reduces contamination from the deposition environment.Typical gas pressures are in a range of 10⁻⁵ Torr to 10⁻⁶ Torr. In otherembodiments, the vacuum deposition is conducted using sputterdeposition, whereby atoms are removed from a solid “target” of theto-be-deposited material by bombardment with accelerated ions. Momentumtransfer causes ejection of surface atoms, which are then deposited ontothe substrate. Sputtering occurs at less than 5×10⁻³ Torr whereparticles do not suffer from collisions with gas molecules in the volumebetween the target and substrate. Sputter deposition includes diode,magnetron and ion beam sputtering.

In yet other embodiments, the vacuum deposition is conducted usinghigh-impulse power magnetron sputtering (HIPIMS), whereby short pulsesof high power are applied to the target on the order of kW/cm². At thesepower levels, ionization of the sputtered material creates a metal-basedplasma. Coatings made by HIPIMS are very dense and smooth in character.In yet other embodiments, the vacuum deposition is conducted using ionplating using energetic ion bombardment during deposition to densify thedeposit and control properties of the coating such as stress andmicrostructure. Ion bombardment during deposition is conducted byaccelerating ions from a plasma directly to the solid material source orby using a separate ion source (e.g., “ion gun”).

A third step 300 of the process according to the embodiment of FIG. 1includes masking 30 a portion of the plumbing fixture 10. In general,the step of masking is conducted to selectively protect a portion of theplumbing fixture 10 that already comprises the first coating 20. Themasking 30 may define a second appearance of the plumbing fixture 10that is different from the first appearance of the first coating. In asubsequent deposition process (i.e., step 400 of FIG. 1), a secondcoating is deposited directly on both the protected and unprotectedportions of the plumbing fixture to define a second finish having asecond appearance different from the first appearance. Therefore,selection of the mask material is based on its ability to selectivelyseparate in a post-deposition wash (i.e., step 500 of FIG. 1), carryingwith it the portion of the second coating deposited on the mask whileleaving the portion of the first coating deposited underneath the maskintact. Moreover, another factor in selecting the mask material is itsoutgassing properties. Similar to the methods of forming the firstcoating, in some embodiments, the second coating is also deposited in avacuum environment. In vacuum environments, one common problem is therelease of gas from the bulk of a material positioned in the vacuumchamber. This outgassing adds to the pressure load in the chamber andaffects film deposition rates and introduces contamination into thedeposited film. For example, for masking materials having a highoutgassing rate would potentially result in contamination of the secondcoating with outgassed elements (adversely affecting the aesthetics ofthe resultant film), as well as reduce deposition rates of the secondcoating due to decreased mean free path for collision between thedepositing material and other gaseous particles between the target andsubstrate. Therefore, to minimize contamination and reduce depositionrates of the second coating, Applicant advantageously utilized a maskingmaterial having a low outgassing rate.

Vacuum-compatible masking materials may be selected from at least one ofmetals, plastics, glasses, ceramics, lubricants, or adhesives.Non-limiting examples of metal masks include: austenitic stainlesssteels, mild steels, aluminum and aluminum alloys, aluminum bronze,nickel and nickel alloys, beryllium, oxygen-free copper, indium, gold,platinum, zirconium, titanium, tungsten, molybdenum, tantalum, niobium,and solders (e.g., tin-silver eutectic (95% Sn, 5% Ag)). Non-limitingexamples of plastic masks include: fluoropolymers (e.g., polyvinylidenefluoride, polytetrafluoroethylene), vespel polyimide, polycarbonates,polystyrene, polyetheretherketone (PEEK), Kapton, and elastomers (e.g.,nitrile rubber, fluorinated elastomers, perfluoroelastomeric compounds).Non-limiting examples of glasses and ceramics include: borosilicateglass, alumina ceramics, and fluorphlogopite mica in borosilicate glassmatrices. Non-limiting examples of lubricants include vacuum greases(e.g., Ramsey grease, fluorether-based greases, polyphenyl ethergreases) and dry lubricants (e.g., molybdenum disulfide, tungstendisulfide, boron nitride, graphite), which are materials that, despitebeing in the solid phase, effectively reduces friction between twoin-contact surfaces without needing a liquid oil medium. In oneembodiment, the vacuum-compatible masking material is a mixturecomprising boron nitride.

In one embodiment, the vacuum-compatible masking material is a drylubricant fabricated by a method selected from the group consisting ofprinting, powder coating, painting, spraying, dipping, brushing, anddry-powder tumbling. For example, a dry lubricant material is initiallydispersed as an additive in a solvent such as an organic solvent, water,or grease. The substrate (e.g., plumbing fixture) may then beselectively spray-coated with the additive-containing solvent and thenallowed to cure until the solvent evaporates, leaving behind a solid,dry lubricant. In one embodiment, a thickness of the masking materialmay greater than the thickness of either the first coating or secondcoating, for example, in a range of about 10 μm to about 100 μm. In oneembodiment where boron nitride is used as the masking material, thecuring is conducted at a range of about 60° C. to about 250° C. (e.g.,80° C.) for a time in a range of about 15 minutes to about 120 minutes(e.g., 20 minutes) for each layer.

For surfaces that are non-planar, the plumbing fixture may be set on aturntable that manually or automatically rotates 360° as the maskingmaterial is applied. The material is sprayed in any desiredpredetermined pattern, but in a graduated fashion to define a gradient.For example, as seen in the embodiment of FIG. 2, one end of theplumbing fixture 202 may be substantially completely (i.e., about 100%)covered with the masking material 204 with a gradient forming as thespray coating is applied further and further away from the 100%-coatedend until the fixture 202 has substantially no (i.e., about 0%) maskapplied over the first coating 206 (i.e., the first coating is mostlyvisible). In another exemplary embodiment shown in FIG. 3, a middleportion of the plumbing fixture 302 is substantially completely coveredwith the masking material 304 with a gradient forming as the spraycoating is applied further and further away in each direction from thesubstantially 100%-coated middle portion until the fixture 302 hassubstantially no mask applied over the first coating 306. It should benoted that any desired pattern for the masking material may be employedaccording to various exemplary embodiments.

FIG. 5 illustrates a process for masking a portion of the plumbingfixture, according to an exemplary embodiment. A plumbing fixture 500 ispositioned atop a rotatable turntable 502 and temporarily affixed to acentrally located rod 504 extending upwards from a top surface of theturntable. The fixture 500 may be affixed to the rod 504 using anyfastening arrangement, such as a clip, pin, adhesive, etc., such thatwhen rotated, the fixture remains secure to achieve a predeterminedpatterning of the masking material 508, which is sprayed using a spraygun 506 (e.g., a pressurized container, etc.). The rod 504 may bemodified depending on the type of fixture upon which the maskingmaterial 508 is being deposited. For example, an extension length and/orwidth of the rod may be altered depending on the dimensions of thefixture to maximize stability of the fixture while rotated.

In some exemplary embodiments, the spray gun 506 is manually held by auser applying the masking material 508. In other exemplary embodiments,the spray gun 506 is held by a robotic arm as the turntable 502 rotates.The turntable rotates at predetermined revolutions per minute in a rangeof about 5 rpm to about 15 rpm. In one example, the turntable may rotateat about 10 rpm. The spray gun 506, whether held manually or by roboticarm, is positioned at a distance in a range of about 6 inches to about24 inches away from the rotating fixture. In one example, the spray gunmay be held at a distance of about 12 inches away from the rotatingfixture. It is also contemplated that the spray gun 506, whether heldmanually or by robotic arm, is rotated around the fixture 500, with thefixture being stationary. As the masking material 508 is sprayed ontothe fixture target, the intensity of the spray stream varies along theangle at which it exits the spray gun 506. In other words, the portionof the fixture 500 which experiences the center of the spray stream willhave a greater density of masking material coated thereon (i.e., morecomplete coverage) than will the portion of the fixture 500 whichexperiences an edge of the spray stream (i.e., less complete coverage).FIG. 5 depicts this phenomena using the dashed lines for the maskingmaterial 508 exiting the spray gun 506.

The spray gun 506 may be moved linearly up and down along a length ofthe fixture to achieve the desired coverage such that below a certainlength of the fixture (e.g., below a position ‘a’) to where the fixturemeets a top surface of the turntable 502, there is substantiallycomplete (e.g., about 100%) coverage of the masking material on thefixture. Above the position ‘a’ is the portion of the fixture, which hasa gradient of masking material coated thereon. Rotation is continueduntil a predetermined masking material pattern is achieved.

A fourth step 400 of the process according to the embodiment of FIG. 1includes depositing a second coating 40 on the plumbing fixture 10 atopboth the protected portion coated with the masking material 30 and theunprotected portion coated by only the first coating 20. In oneembodiment, a thickness of the second coating may vary in a range ofabout 100 nm to about 2000 nm. As described above, the second coatingmay be deposited using a deposition technique, which is the same as ordifferent from the deposition technique used for fabricating the firstcoating.

A fifth step 500 of the process according to the embodiment of FIG. 1includes removing the mask 30 from the plumbing fixture 10 to achieve afinal ombré appearance (i.e., a dual-coated, graded appearance) wherebythe fixture 10 comprises the first coating 20 having a first appearance,the second coating 40 having a second appearance different from thefirst appearance, and a transition region 50 representing the gradualtransition of the first coating 20 to the second coating 40, orvice-versa. In one exemplary embodiment, the transition region 50includes a first percentage of the first coating and a second percentageof the second coating. The first percentage is in the range of about 5%to about 95%, with the remaining balance as the second percentage. Inone exemplary embodiment, the transition region 50 includes a pluralityof percentages of the first coating and a plurality of percentages ofthe second coating.

FIG. 4 illustrates one example of a faucet plumbing fixture having afinal ombré appearance whereby a first coating is positioned toward afirst end of the faucet, a second coating is positioned toward a secondend of the faucet, and a transition region is positioned therebetween.

In one embodiment, the removing step includes a chemical separationprocess, whereby after the third step 300 of masking a portion of theplumbing fixture and the fourth step 400 of depositing the secondcoating atop both the protected portion coated with the masking materialand the unprotected portion coated by only the first coating, thesacrificial mask material is washed out together with overlying portionsof the second coating to leave exposed portions of the first coatingthat was protected by the mask. Selection of chemical solvents areevaluated for selective removal of the mask material. In other words,solvents must be chosen to selectively disengage the masking materialfrom the first coating without substantially attacking either the firstcoating or the second coating.

In one exemplary embodiment, where boron nitride was used as the maskmaterial, an acid wash was conducted comprising water and a mixture ofacids such as sulfuric acid (H₂SO₄) and hydrofluorosilicic (HFC) acid.Other acids which may be included in the mixture include mineral acids(e.g., nitric acid (HNO₃), hydrochloric acid (HCl), hydrofluoric acid(HF), and phosphoric acid (H₃PO₄)) and organic acids (acetic acid(CH₃COOH) and formic acid (CH₂O₂)). The acid components of the acid washfacilitate removal of boron nitride by affecting the residual suspensionbinder (e.g., bentonite, alumina bentonite, or alumina) phases or byslightly dissolving the substrate enough to get the boron nitride layerto release. The pH of the acid wash solution may be in a range of 1 to5. One example of a contemplated acid wash is an aqueous solutioncomprising a mixture of 3.5% concentrated sulfuric acid and a 23%hydrofluorosilicic acid solution at about 40° C. In another exemplaryembodiment, water-based or organic solvent-based boron nitride coatingsmay be removed by exposure to water or solvent (e.g., ethanol, acetone,or combinations thereof), respectively.

In yet another exemplary embodiment, masking materials may also beremoved using frictional mechanical techniques such as lightsandpapering, wire-brushing, grit-blasting or shot-blasting, CO₂ (dryice) blasting, or ultrasonic-cleaning baths. Although the presentapplication discusses examples in which the surface transitions from onecoating to another, it is possible that additional transitions may beprovided according to other exemplary embodiments (e.g., three or morecolors may be used, with a graduated transition between each usingsimilar masking and deposition processes as described herein).

In another embodiment, the ombré appearance may also be achieved withoutthe masking material as described herein. For example, it iscontemplated that the gradient of the second coating is positioned onthe first coating without having to remove the plumbing fixture from thevacuum chamber after deposition of the first coating. As shown in FIG.6, plumbing fixture 600 remains in the vacuum chamber after depositionof the first coating and is partially covered with a shroud 602 suchthat a first portion 604 is completely exposed to the vacuum environmentfor deposition of the second coating. First portion 604 (i.e., belowline a) will experience substantially complete (i.e., about 100%)coverage with the second coating. After coating of the first portion 604is complete the shroud 602 is gradually and continuously shifted upwardstill some amount of the second coating reaches a predetermined positionb along the plumbing fixture 600. The section of the plumbing fixturebetween a and b represents the transition region 606 (e.g., see alsoFIG. 1) where there is a gradual transition from the second coating tothe first coating. Position b′ represents the maximum height along theplumbing fixture to which the shroud 602 may be shifted and is along thesame horizontal plane as the portion 608 of the fixture comprisingsubstantially complete (i.e., about 100%) coverage with the firstcoating. In other words, above position b (and therefore b′), thefixture comprises substantially no (i.e., about 0%) coverage with thesecond coating (and about 100% coverage with the first coating). Theshroud may be shifted at a constant or varying linear speed, with theshift rate dependent on the desired pattern of the ombré appearance. Insome exemplary embodiments, the fixture may be rotated within the vacuumchamber during deposition.

In yet another embodiment, the ombré appearance may also be achievedwithout the masking material as described herein. For example, it iscontemplated that the ombré appearance may be applied using a single,continuous PVD process whereby a first flow of material comprising afirst coating gradually transitions to a second flow of materialcomprising a second coating as a shroud is gradually shifted across adimension of the plumbing fixture. Much like the embodiment of FIG. 6,the shroud may be shifted at a constant or varying linear speed, withthe shift rate dependent on the desired pattern of the ombré appearance.In some exemplary embodiments, the fixture may be rotated within thevacuum chamber during deposition.

FIG. 7 illustrates one exemplary embodiment of the single, continuousPVD process, whereby a fixture 700 is placed inside a PVD chamber andshrouded 708 to expose only a first portion 702 of the fixture 700 wheresubstantially complete coverage of the first coating is desired. Thefirst flow of material comprising the first coating enters the chamberand the exposed first portion 702 is coated (i.e., about 100%) with thefirst coating. Upon completion of coating the first portion 702, thefirst portion 702 is shrouded and at the same time, the first flow isgradually decreased while the second flow of material comprising thesecond coating is gradually increased. In other words, a second portion704 which is the transition segment and positioned adjacent to the firstportion 702 is exposed to the dual first and second flow. For example,the second portion 704 may be divided into a predetermined number ofregions, with each subsequent region being positioned gradually awayfrom the first portion 702 (e.g., first region 704 a adjacent to firstportion 702, second region 704 b adjacent to first region 704 a andseparated from first portion 702 by first region 704 a, third regionadjacent to second region and separated from first portion by first andsecond regions, etc.). In the coating process of the second portion 704,only the first region 704 a of the second portion 704 is exposed to thedual flow, which would comprise mostly the first material and a traceamount of second material. After the first region 704 a is coated, thefirst region 704 a is shrouded and the second region 704 b is exposed tothe dual flow, this time with a decreased amount of first material andan increased amount of second material as in the first region 704 a.This process continues until the last region 704 n of the second portion704 experiences a dual flow comprising mostly the second material and atrace amount of first material. After the second portion 704 (i.e., thetransition segment) is complete, both the first portion 702 and thesecond portion 704 are shrouded and a third portion 706 of the fixture,where substantially complete coverage of the second coating is desired,is exposed to the second flow of material comprising the second coatingto achieve substantially complete coverage (i.e., about 100%) with thesecond coating.

The present disclosure describes a novel method for forming a multicolorfinish. Benefits of the fabrication methods described herein includeforming a dual-coated, graded appearance having a transition region(from the first appearance coating to the second appearance coating)without any apparent cloudiness or diffused finish distortion ortransition region defects. Moreover, the use of PVD deposition informing the first and second coatings results in robust, long-lastingfinishes at mostly any desired purity to achieve predetermined aestheticstandards for the plumbing fixture.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

The construction and arrangement of the elements of the multi-coloredfinishes for plumbing fixtures and methods of fabrication thereof asshown in the exemplary embodiments are illustrative only. Although onlya few embodiments of the present disclosure have been described indetail, those skilled in the art who review this disclosure will readilyappreciate that many modifications are possible (e.g., variations insizes, dimensions, structures, shapes and proportions of the variouselements, values of parameters, mounting arrangements, use of materials,colors, orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied.

Additionally, the word “exemplary” is used to mean serving as anexample, instance, or illustration. Any embodiment or design describedherein as “exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments or designs (and such term is notintended to connote that such embodiments are necessarily extraordinaryor superlative examples). Rather, use of the word “exemplary” isintended to present concepts in a concrete manner. Accordingly, all suchmodifications are intended to be included within the scope of thepresent disclosure. Other substitutions, modifications, changes, andomissions may be made in the design, operating conditions, andarrangement of the preferred and other exemplary embodiments withoutdeparting from the scope of the appended claims.

Other substitutions, modifications, changes and omissions may also bemade in the design, operating conditions and arrangement of the variousexemplary embodiments without departing from the scope of the presentinvention. For example, any element disclosed in one embodiment may beincorporated or utilized with any other embodiment disclosed herein.Also, for example, the order or sequence of any process or method stepsmay be varied or re-sequenced according to alternative embodiments. Anymeans-plus-function clause is intended to cover the structures describedherein as performing the recited function and not only structuralequivalents but also equivalent structures. Other substitutions,modifications, changes and omissions may be made in the design,operating configuration, and arrangement of the preferred and otherexemplary embodiments without departing from the scope of the appendedclaims.

While this specification contains many specific exemplary embodimentdetails, these should not be construed as limitations on the scope ofany inventions or of what may be claimed, but rather as descriptions offeatures specific to particular embodiments of particular inventions.Certain features that are described in this specification in the contextof separate embodiments can also be implemented in combination in asingle embodiment. Conversely, various features that are described inthe context of a single embodiment can also be implemented in multipleembodiments separately or in any suitable sub-combination. Moreover,although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to asub-combination or variation of a sub-combination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, multitasking and parallel processingmay be advantageous. Moreover, the separation of various systemcomponents in the embodiments described above should not be understoodas requiring such separation in all embodiments, and it should beunderstood that the described program components and systems cangenerally be integrated together in a single software product orpackaged into multiple software products.

Thus, particular embodiments of the subject matter have been described.In some cases, the actions recited herein can be performed in adifferent order and still achieve desirable results. In addition, theprocesses depicted in the accompanying figures do not necessarilyrequire the particular order shown, or sequential order, to achievedesirable results. In certain exemplary embodiments, multitasking andparallel processing may be advantageous.

What is claimed is:
 1. A plumbing fixture having a multi-colorappearance comprising: a first portion comprising a first finish havinga first appearance; a second portion comprising a second finish having asecond appearance that differs from the first appearance; a transitionregion between the first portion and the second portion, wherein theappearance of the third region is graduated from the first appearance tothe second appearance between a first end of the transition regionadjacent the first portion and a second end of the transition regionadjacent the second portion; whereby the plumbing fixture has an ombréappearance as a result of the graduated transition between the firstportion and the second portion.
 2. The plumbing fixture of claim 1,wherein the plumbing fixture is selected from the group consisting of afaucet, a soap dispenser, a faucet handle, water piping, a hose, a sink,a bathtub, a whirlpool, and a spa.
 3. The plumbing fixture of claim 1,wherein the transition region comprises the first finish at a firstpercentage in a range of about 5% to about 95% with the remainingbalance as a second percentage of the second finish.
 4. The plumbingfixture of claim 1, wherein the first finish and the second finish areselected from at least one of polished chrome, brushed chrome, polishedFrench gold, polished titanium, brushed titanium, polished rose gold,polished modern gold, polished tungsten, polished modern brass, satintitanium, polished satin chrome, satin bronze, polished brass, satinbrass, oil-rubbed bronze, polished nickel, brushed nickel, or matteblack.
 5. The plumbing fixture of claim 1, wherein the first finish andthe second finish are physical vapor deposition (PVD) finishes, chemicalvapor deposition (CVD) finishes, atomic layer deposition (ALD) finishes,electroplating finishes, dip coating finishes, or spray coatingfinishes.
 6. The plumbing fixture of claim 1, wherein the first finishor the second finish is deposited on the third portion at varyingintensities along different angles relative to the plumbing fixture. 7.The plumbing fixture of claim 1, further comprising: a priming layer onthe plumbing fixture disposed between the plumbing fixture and the firstfinish or between the plumbing fixture and the second finish.
 8. Amulti-color plumbing fixture comprising: a first portion having a firstappearance; a second portion having a second appearance that differsfrom the first appearance; a third portion extending between the firstportion and the second portion, wherein the third portion has anappearance that transitions in graduated fashion from the firstappearance at a first end thereof adjacent the first portion to thesecond appearance at a second end thereof adjacent the second portion.9. The plumbing fixture of claim 8, wherein the plumbing fixture isselected from the group consisting of a faucet, a soap dispenser, afacet handle, water piping, a hose, a sink, a bathtub, a whirlpool, anda spa
 10. The plumbing fixture of claim 8, wherein the first appearancecomprises a first finish and the second appearance comprises a secondfinish.
 11. The plumbing fixture of claim 10, wherein the first finishand the second finish are selected from at least one of polished chrome,brushed chrome, polished French gold, polished titanium, brushedtitanium, polished rose gold, polished modern gold, polished tungsten,polished modern brass, satin titanium, polished satin chrome, satinbronze, polished brass, satin brass, oil-rubbed bronze, polished nickel,brushed nickel, or matte black.
 12. The plumbing fixture of claim 8,wherein third portion comprises a first percentage in a range of about5% to about 95% of the first appearance with the remaining balance as asecond percentage of the second appearance.
 13. The plumbing fixture ofclaim 8, wherein the third portion includes a plurality of percentagesof the first appearance and a plurality of percentages of the secondappearance.
 14. The plumbing fixture of claim 9, wherein the firstfinish and the second finish are physical vapor deposition (PVD)finishes, chemical vapor deposition (CVD) finishes, atomic layerdeposition (ALD) finishes, electroplated finishes, dip coated finishes,or spray coated finishes.
 15. A multi-color plumbing fixture formed by aprocess comprising: depositing a first coating on the plumbing fixture;selectively applying a masking material in a graduated fashion over atleast a portion of the first coating to define a gradient from a firstportion of the plumbing fixture that is substantially completely coveredby the masking material to a second portion of the plumbing fixture thathas substantially no masking material; depositing a second coating overthe masking material; and removing the masking material from theplumbing fixture such that the plumbing fixture has a surface finishincluding a transition region representing a gradual transition betweenthe first coating and the second coating; wherein selectively applyingthe masking material in a graduated fashion comprises spraying themasking material at varying intensities.
 16. The plumbing fixture ofclaim 15, wherein the transition region comprises a first percentage ofthe first coating and a second percentage of the second coating.
 17. Theplumbing fixture of claim 16, wherein the first percentage is in a rangeof about 5% to about 95% with the remaining balance as the secondpercentage.
 18. The plumbing fixture of claim 15, wherein the transitionregion includes a plurality of percentages of the first coating and aplurality of percentages of the second coating.
 19. The plumbing fixtureof claim 15, wherein the first coating defines a first finish having afirst appearance, and wherein the second coating defines a second finishhaving a second appearance that is different from the first appearance.20. The plumbing fixture of claim 15, wherein the masking materialincludes at least one of molybdenum disulfide, tungsten disulfide, boronnitride, or graphite.